Gasket singulation and insertion apparata and methods

ABSTRACT

A gasket singulation apparatus for separating one gasket from a web-connected stack of gaskets includes a mandrel for receiving the web-connected stack and an arrangement of cylinders which are used to support the web-connected stack of gaskets and to pull one gasket away from the remainder of the web-connected stack so as to singulate that one gasket. A first plurality of cylinders are used to support the web-connected stack. A second plurality of cylinders are used to pierce any connecting material between the gasket to be singulated and the remainder of the stack. Once the web material is pierced, cylinder movement is effected so as to pull the selected gasket away from the stack, allowing any connecting material to sever and thereby singulate one gasket from the stack. Once the gasket is singulated, various insertion mechanisms are disclosed for inserting the singulated gasket into a pail lid groove.

BACKGROUND OF THE INVENTION

[0001] The present invention relates in general to apparata for thesingulation of a gasket from a plurality of gaskets and the subsequentinsertion of the singulated gasket into a receiving groove which isformed in another structure, such as a plastic or metal pail lid.

[0002] More specifically, the present invention relates to thesingulation of a synthetic material gasket from a joined pluralitywherein adjacent ones of the individual gaskets are initially joinedtogether by a thin web of material. Singulation of a single gasket fromthe joined plurality is achieved by cutting, tearing, or in some fashionsevering the joining or connecting web of material which is positionedbetween adjacent gaskets in the stack. Once a single gasket is free fromthe joined plurality or stack of gaskets, it is available to be handledby automated equipment so as to be positioned for insertion into theselected receiving channel or groove in the other structure.

[0003] When the receiving groove is part of a metal or plastic pail lid,the pail lid movement is also automated and timed with the gasketseparation (i.e., singulation) steps. The selected pail lid, which isone of a plurality of sequentially staged or indexed pail lids, is movedinto position as part of the overall insertion mechanism or apparata,according to the present invention. The gasket is moved into positionand the insertion of the gasket into the pail lid groove is completed.Thereafter, the pail lid and gasket assembly is moved off line forsubsequent processing.

[0004] While the use of synthetic gaskets in pail lids and similarstructures is well known, the gaskets which are used are typicallysupplied to the manufacturer as individual gaskets, packaged in bulk.This means that these gaskets are provided to the end user, in thecontext of the one performing the installation step, in a turned,twisted, and tangled mass, very similar to a box of rubber bands whensupplied in bulk. The particular gaskets which are associated with thepresent invention can range from as small as 1-½ inches in diameter toas large as 68 inches in diameter with virtually any cross sectionaldiameter in the case of O-ring styles, or with other overall and crosssectional shapes, depending on the application. Suitable materials forthese gaskets include a wide range of elastomeric compounds and thegaskets which are ultimately fabricated can be solid or hollow (tubular)in lateral section. Regardless of the size, shape, or material of thegaskets, one common denominator is the turned, twisted, and tangledarrangement of such gaskets when they are supplied in bulk form. As aconsequence, this bulk supply requires manual separation of the gasektsin order to prepare each gasket individually for its subsequentinsertion into a pail lid. Whether the gaskets are manually loaded oneat a time for insertion, or whether the gaskets are loaded or staged inmultiple units for use with automated insertion equipment, each gasketmust still be manually separated from the bulk supply, untangled,untwisted, and typically laid flat, at least for most of the present-dayinsertion equipment. This step of manually untangling each gasket andpreparing it in a flat and untwisted form for insertion into a pail lidor similar structure is a time consuming, labor intensive step that addsto the finished pail lid cost. The additional time for this step canalso have a bearing on the overall cycle time and through put rate forthe pail lid and gasket combination.

[0005] Considering the current gasket handling procedures as describedabove, it would be an improvement if the manual, gasket untangling stepcould be eliminated and the entire process automated. This assumes thatit would be possible to prepare singulated gaskets without twist andgenerally laid out into a circular form for the automated insertionprocess. Regardless of the singulation method and mechanism, it isimportant to have a supply of gaskets so that the repetitive cycle ofgasket insertion, pail lid after pail lid, will have only minimal downtime and infrequent cycle interruptions for the purposes of loading,securing, or staging a new supply of gaskets for the supply of paillids.

[0006] The present invention provides an improvement to the current(typical) gasket insertion procedures by providing an automatedmechanism and a unique sequence of steps to singulate each gasket from aplurality and to do so such that each singulated gasket is prepared forinsertion into a pail lid, without any tangles and/or twists.

[0007] Gaskets of the type described herein are typically initiallymolded in the form of a generally cylindrical tube or coil with a seriesof gaskets sequentially stacked with a very thin connecting web ofmaterial between adjacent gaskets. This is the most efficient moldingmethod and design, from the perspective of mold design costs andeffectiveness, such that any waste is minimized. It is also important tonote that the gaskets which are molded in this fashion are each alignedin a substantially flat orientation in a circular shape, at least forthe O-ring shaped gaskets, and there are no twists, turns, or tanglesbetween any of the gaskets of the molded stack. The generally circularform of each gasket accounts for the generally cylindrical configurationof the joined stack.

[0008] At the present time, the molder of such gaskets simply singulatesthe gaskets, one from the others, by severing the connecting web ofmaterial and then merely tossing each singulated gasket into a bulkcontainer. Since no time is taken nor any care exercised as to how thegaskets are oriented when singulated and placed into the bulk container,this is where the tangling and twisting begins. If the gaskets are thenparceled out into smaller lot quantities for individual orders,additional twisting and tangling can occur. While it might be possiblefor the OEM molder of the gaskets to carefully singulate and arrangeeach gasket, free of tangles and twists, the finished singulated gasketswould still have to be stacked or stored in some fashion in order tokeep each one twist and tangle free. Similar care would have to be takenduring shipment and this would inevitably add to the overall unit costof each gasket. One of the realities of trying to singulate and prepareeach gasket in a tangle-free and twist-free form is the type and styleof automated equipment the end users might have. To be most effective,the gasket should be supplied in a form ready to use. This is obviouslyall wasted if the end user has no desire to automate the gasketinsertion process. For example, the gaskets might be supplied with otherequipment or parts where a tangled form or twist in the gasket isacceptable. Since there would be an added cost to carefully singulateeach molded gasket if some, but not all, customers want tangle-free andtwist-free gaskets, then the orders would have to be documented andsegregated at the time of molding. Otherwise, all of the gaskets wouldhave to be singulated and stocked in the same manner. What is done nowis to simply bulk package the singulated gaskets, under the theory thatthe lower the unit cost the better and thereby let the end user dealwith any twist and tangle problems.

[0009] The present invention is designed to accept the tubular (coiled)form of the plurality of molded gaskets, still connected together withthe thin web of material between adjacent gaskets. This coiled form orstack of gaskets is utilized in the automated singulation equipment andmethods of the present invention in the same way or form that it ismolded by the OEM supplier. The molder does not have to singulate eachgasket from the cylindrical stack which actually could lower the unitcost of each gasket. By allowing the design of the present invention tosingulate each gasket in an automated fashion and to be inserteddirectly into the pail lid following singulation, no gasket twist isintroduced by any of the intermediate processing steps. The results ofthe apparata and methods of the present invention are to fully automateboth the gasket singulation step and the gasket insertion step in anovel and unobvious manner.

SUMMARY OF THE INVENTION

[0010] A gasket singulation apparatus for separating one gasket from aweb-connected stack of gaskets according to one embodiment of thepresent invention comprises a mandrel for receiving the web-connectedstack of gaskets, first support means for positioning the web-connectedstack of gaskets at a predetermined location relative to the mandrel,separation means for piercing any web material between a selected pairof axially adjacent gaskets, drive means for axially moving theseparation means so as to pull one gasket of the selected pair away fromthe other gasket of the selected pair, and second support means forsupporting those gaskets remaining as part of the web-connected stack asthe one gasket is separated from the original web-connected stack.

[0011] Also included as part of the present invention is a gasketinsertion apparatus for inserting a gasket into an annular receivinggroove in a pail lid. The gasket insertion apparatus, according to oneembodiment of the present invention, comprises a gasket positioningmandrel defining an annular support lip, pail lid positioning means formoving a pail lid into a gasket-insertion position adjacent the annularsupport lip, wherein the annular receiving groove opens toward theannular support lip and gasket insertion means for engaging a gasketwhich is to be positioned on the annular support lip, the gasketinsertion means including a gasket-contacting portion and two drivemechanisms wherein one drive mechanism is constructed and arranged formoving the gasket-contacting portion radially and the other drivemechanism is constructed and arranged for moving the gasket-contactingportion axially.

[0012] Also included as part of the present invention is a gasketsingulation method for separating one gasket from a web-connected stackof gaskets, this particular method according to the present inventionutilizes the gasket singulation apparatus described herein.

[0013] Additionally, the present invention includes a gasket insertionmethod for inserting a gasket into a generally annular receiving grooveof a pail lid, wherein the gasket insertion method, according to thepresent invention, utilizes the gasket insertion apparatus describedherein.

[0014] One object of the present invention is to provide an improvedgasket singulation apparatus. Another object of the present invention isto provide an improved gasket insertion apparatus. Another object of thepresent invention is to provide an improved method of gasketsingulation. A still further object of the present invention is toprovide an improved method of gasket insertion.

[0015] Related objects and advantages of the present invention will beapparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a diagrammatic, front elevational view of a gasketsingulation apparatus according to a typical embodiment of the presentinvention.

[0017]FIG. 2 is a diagrammatic, top plan view of selected portions ofthe FIG. 1 apparatus.

[0018]FIG. 3 is a diagrammatic, partial, enlarged front elevational viewof the FIG. 1 apparatus.

[0019]FIG. 4 is a diagrammatic, partial, enlarged front elevational viewof the FIG. 1 apparatus illustrating a first step of the gasketsingulation method utilizing the FIG. 1 apparatus.

[0020]FIG. 5 is a diagrammatic, partial, enlarged front elevational viewof the FIG. 1 apparatus illustrating a second step of the gasketsingulation method utilizing the FIG. 1 apparatus.

[0021]FIG. 6 is a diagrammatic, partial, enlarged front elevational viewof the FIG. 1 apparatus illustrating a third step of the gasketsingulation method utilizing the FIG. 1 apparatus.

[0022]FIG. 7 is a diagrammatic, partial, enlarged front elevational viewof the FIG. 1 apparatus illustrating a first step of the gasketinsertion method utilizing the FIG. 1 apparatus.

[0023]FIG. 8 is a diagrammatic, partial, enlarged detail, frontelevational view of the FIG. 1 apparatus illustrating a second step ofthe gasket insertion method utilizing the FIG. 1 apparatus.

[0024]FIG. 9 is a diagrammatic, partial, enlarged front elevational viewof the FIG. 1 apparatus illustrating a third step of the gasketinsertion method utilizing the FIG. 1 apparatus.

[0025]FIG. 10 is a diagrammatic, partial, enlarged front elevationalview in full section illustrating the first step in beginning to recyclethe equipment to the cycle starting point of FIG. 4.

[0026]FIG. 11 is a diagrammatic, partial, enlarged front elevationalview in full section illustrating the second step in beginning torecycle the equipment to the cycle starting point of FIG. 4.

[0027]FIG. 12 is a diagrammatic, top plan view illustrating theinsertion equipment for the FIG. 1 apparatus.

[0028]FIG. 13 is a diagrammatic, perspective view of a gasketsingulation and insertion apparatus according to another embodiment ofthe present invention.

[0029]FIG. 14 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the first step in the overall singulation andinsertion method.

[0030]FIG. 15 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the second step in the overall singulation andinsertion method.

[0031]FIG. 16 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the third step in the overall singulation andinsertion method.

[0032]FIG. 17 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the fourth step in the overall singulation andinsertion method.

[0033]FIG. 18 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the fifth step in the overall singulation andinsertion method.

[0034]FIG. 19 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the sixth step in the overall singulation andinsertion method.

[0035]FIG. 20 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the seventh step in the overall singulation andinsertion method.

[0036]FIG. 21 is a diagrammatic, side elevational view of the FIG. 13apparatus, illustrating the eighth step in the overall singulation andinsertion method.

[0037]FIG. 22 is a diagrammatic, perspective view of the gasketinsertion mechanism comprising one portion of the FIG. 13 apparatus.

[0038]FIG. 23 is a diagrammatic, top plan view of the FIG. 22 mechanism.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] For the purposes of promoting an understanding of the principlesof the invention, reference will now be made to the embodimentsillustrated in the drawings and specific language will be used todescribe the same. It will nevertheless be understood that no limitationof the scope of the invention is thereby intended, such alterations andfurther modifications in the illustrated device, and such furtherapplications of the principles of the invention as illustrated thereinbeing contemplated as would normally occur to one skilled in the art towhich the invention relates.

[0040] Referring to FIGS. 1, 2, and 3, there is diagrammaticallyillustrated a gasket singulation and insertion mechanism 20 according toone embodiment of the present invention. Mechanism 20 includes, incombination, a gasket singulation mechanism 21 and a gasket insertionmechanism 22. The gasket singulation mechanism 21 can be used with othergasket insertion mechanisms and, conversely, the gasket insertionmechanism 22 can be used with other gasket singulation mechanisms. Theending step or stage of the gasket singulation process, using mechanism21, is the separation of a single gasket 23 from the joined tubular orcylindrical stack 24 of gaskets 23. The starting or beginning step orstage of the gasket insertion process, using mechanism 22, is thehandling of the singulated gasket 23 resulting from the gasketsingulation process.

[0041] Considering the gasket singulation mechanism 21 and thecorresponding method steps, the joined tubular stack 24 of gasket 23, isprovided with an initial horizontal orientation, supported by holder 27.This is the broken line form for stack 24, as illustrated in FIG. 1.Holder 27, also illustrated in broken line form, is constructed andarranged to pivot (hinge) at joint 28 so that the horizontal orientationof stack 24 is changed to a vertical orientation for sliding ontocylindrical mandrel 29. A cylindrical support sleeve 30 is included tosupport stack 24 in the horizontal orientation and maintain the desiredcylindrical shape of stack 24. When the stack 24 is moved to a verticalorientation, the stack 24 is able to slide off of the sleeve 30 downonto mandrel 29.

[0042] Mandrel 29 is a hollow, cylindrical member and positioned in theinterior are an equally-spaced series of eight pneumatic air cylinders31. All eight pneumatic cylinders 31 are illustrated in FIG. 2 whileonly one cylinder 31 is illustrated in FIGS. 1 and 3, merely toillustrate the axial location of all eight cylinders 31 without overlycomplicating the drawings. Each cylinder 31 is securely mounted in ahorizontal orientation, relative to axial centerline 35, into anaperture 32 in the sidewall 33 of mandrel 29. Each aperture 32 is athrough opening such that the plunger or piston 34 of the cylinder isable to extend through the sidewall 33 as illustrated in FIG. 3. In thisextended orientation for each cylinder 31, the pistons 34 (eight total)are able to support the joined tubular stack 24 of gaskets 23 in thevertical orientation. It is the lower edge of the stack 24 that simplyrests on top of the eight pistons 34 with the cylinders activated intotheir extended orientation.

[0043] Positioned on the exterior of mandrel 29, though not connected tomandrel 29, is a series of eight equally-spaced pneumatic air cylinders,four of which are identified as cylinders 37 a and four of which are, inan alternating pattern, all identified as cylinders 37 b. The piston 38of each cylinder 37 a is fitted with a gasket separating tip 39 which ispointed so as to be easily and accurately positioned between thelowermost gasket 23 of the axial stack 24 and the remainder of thegaskets 23. Each cylinder 37 a is rigidly secured to a support arm 40which in turn is connected to the piston 41 of a pneumatic air cylinder42. Stationary support 43 is used to align and locate each cylinder 42.Considering the illustrated combination of cylinders 37 a and 42, itshould be understood that this connected subassembly is repeated threemore times (four total) at equally-spaced locations around the exteriorof mandrel 29.

[0044] The series of four, equally-spaced cylinders 37 b are used asgasket-supporting cylinders while cylinders 37 a as used asgasket-separating cylinders. In the illustrations of FIGS. 1 and 3, onlya portion of one cylinder 37 b is included as a representative exampleof how all four cylinders 37 b are positioned and utilized. Thecylinders 37 b are axially stationary such that the extension andretraction of each piston 44 is horizontal, i.e., perpendicular to axialcenterline 35, along a fixed plane. The piston 44 of each cylinder 37 bis fitted with a separating/support tip 44 a. While tip 44 a is similarin many respects to tip 39, their ultimate functions are different.

[0045] Tip 39 is extended into mandrel 29 so as to puncture theconnecting web of material between adjacent gaskets 23. The same isachieved by tip 44 a in its extended position. Once the pistons 34 areretracted, the four cylinders 37 a are lowered, via the extension ofpistons 41, so as to pull the bottom (lowermost) gasket 23 free from theremainder of the gaskets which remain connected as part of stack 24. Thepulling of the bottom or lowermost gasket 23 free from the remainder ofthe gaskets in stack 24 is achieved by actually tearing the connectingweb of material between adjacent gaskets so as to sever completely thisconnecting web. As this bottom or lowermost gasket 23 is separated fromthe stack 24, the four cylinders 37 b are used to hold or support theremainder of the gaskets 23 in stack 24.

[0046] Once the lowermost gasket is freed, i.e., singulated, it is ableto drop down onto the annular lower lip 48 of mandrel 29. Lower lip 48is inclined outwardly and downwardly such that a singulated gasket reststhereon without falling off due to the larger diameter at the bottomedge. With the singulated gasket thus positioned, the pistons 38 arefirst retracted and then pistons 41 of cylinders 42 are retracted so asto raise or lift cylinders 37 a back to their cycle-starting (at rest)position. The next step is to energize the eight cylinders 31 so thatthe corresponding pistons 34 are extended back to their cycle-startingpositions. Once the pistons 34 are in position, the pistons 44 ofcylinders 37 b are retracted. This allows the remaining gaskets 23 instack 24 to drop down onto the pistons 34. This signifies the start ofthe new gasket-separation (singulation) cycle.

[0047] Each cylinder 37 a is positioned in a generally horizontalorientation relative to axial centerline 35 and each cylinder 42 ispositioned in a generally vertical orientation, with its axialcenterline being substantially parallel to axial centerline 35. Eachcylinder 37 b is positioned in a generally horizontal orientationrelative to axial centerline 35. While cylinders 31, 37 a, 37 b and 42are preferably pneumatic air cylinders, other devices can be used. Forexample, another option would be to use hydraulic cylinders or ballscrew devices. Other options would include the use of solenoids. One ofthe important features with regard to cylinders 37 a, 37 b, and 42 is tobe able to control precisely the distance of travel and the endinglocation, especially for tips 39 and 44 a and to a lesser extent theending location for cylinders 37 a. In order to fine tune the end pointlocations, the holder 49 for tip 39, the holder 50 for tip 44 a, andsupport arm 40 are internally threaded. Pistons 38, 44, and 41 areexternally threaded for receipt of their corresponding holder or arm. Inthis way, the degree or extent of threaded engagement precisely sets theend point location for tips 39 and 44 a against mandrel 29. The distanceof travel for cylinders 37 a is also precisely set (a sufficientdistance) to ensure that the lowermost gasket 23 actually separates fromthe stack 24.

[0048] With one gasket 23 separated from the stack 24 (i.e.,“singulated”) and resting on top of annular lower lip 48, the gasketinsertion step or cycle is ready to begin. With continued reference toFIGS. 1 and 3, the gasket insertion cycle of the preferred embodimentrequires a gasket inserter subassembly 56 to be positioned outwardly ofmandrel 29. It is believed that two such gasket inserter subassemblies56 will be sufficient if positioned 180 degrees apart (see FIG. 12).However, an increased number of gasket inserter subassemblies can beused and would preferably be positioned with equal spacing so as tobalance the insertion forces around the circumference of the singulatedgasket 23. It is also to be understood that the movements, timing, andcycling of each subassembly 56 is substantially identical for all suchsubassemblies so as to be generally simultaneous. Each gasket insertersubassembly 56 includes a pneumatic air cylinder 57 for horizontaltravel of piston 58 so as to move insertion tip 59 toward (extended) andaway from (retracted) mandrel 29. Also included as part of subassembly56 is a second pneumatic air cylinder 60 which is secured to support 61.Air cylinder 60 is constructed and arranged for vertical travel ofpiston 62 and aligned substantially parallel to axial centerline 35.Piston 62 is threadedly connected to support rod 63 which is securelyattached to cylinder 57. This construction allows cylinder 57 to beraised and lowered by the action of cylinder 60 which in turn raises andlowers insertion tip 59. The inward movement of insertion tip 59positions the gasket-contacting portion 64 over the singulated gasket 23which is resting on top of lower lip 48. With an inverted pail lid 65raised into position adjacent lower lip 48, the downward movement of tip59 by way of the action of cylinder 60 brings portion 64 into contactwith the singulated gasket. The inclined upper surface 66 of lower lip48 causes the gasket 23 to move radially outwardly such that thisportion of the gasket (i.e., that section adjacent insertion top 59) ispushed off of the lower lip 48 into alignment with the annular receivinggroove 67 of the pail lid 65. It will be noted that the annularreceiving groove 67 opens upwardly in the direction of the annular lowerlip on the mandrel so that the travel of the singulated gasket 23 off ofthe mandrel lower lip causes it to move directly into the receivinggroove 67. The receiving groove 67 typically includes a more narrowopening and below that a wider base. Consequently, once the gasket ispushed past the more narrow opening, it is captured and retained withinthe remainder of the receiving groove.

[0049] In view of the preferred materials for gasket 23, and in view ofthe preferred cross sectional size and shape, the single point ofcontact of one insertion tip 59 via portion 64 against the gasket inorder to push the gasket 23 into the pail lid groove 67 actually causesa larger section of gasket 23 to be inserted into the receiving groove.This larger section is generally symmetrical on each side of tip 59 andideally would cover approximately 180 degrees of the gasketcircumference. This in turn would enable full or complete gasketinsertion using only two gasket inserter subassemblies 56, as nowillustrated in FIG. 12. If the circumferential length of the gasketsection which is inserted by each subassembly is less than 180 degrees,then a third or more gasket inserter subassemblies will be required. Thenumber of gasket inserter subassemblies 56 may also need to be increaseddepending on the narrow opening within the pail lid groove. If thatopening is tighter, thereby causing or requiring greater force forinsertion, the section of the gasket which can be inserted by a singlegasket inserter subassembly 56 may not extend 180 degrees and thus wouldrequire at least one more and possibly additional insertersubassemblies.

[0050] While the preferred embodiment of the present invention isdescribed in the context of a pail lid, either plastic or metal, thedescribed gasket singulation apparatus and method of use of FIGS. 1-3 isbasically independent of the receiving structure. Although the circularform of gasket 23 is preferably styled for an annular receiving groove,the singulated gasket could effectively be inserted into any groove orchannel, so long as the circumferential length of the gasket matches thedesired length of the groove. If the groove has a shape other thanannular or cylindrical, a different scheme for the insertion could berequired, at least for the turning or indexing. The described apparatusand method of gasket singulation of FIGS. 1-3 can also be used, at leastin part, for gaskets formed into a web-connected stack, but with agasket shape other than annular.

[0051] The gaskets 23 described for the present invention can range fromas small as 1-½ inches in diameter up to as large as 68 inches indiameter with virtually any cross sectional diameter shape, at least forO-ring styles. Each gasket throughout this size range can be hollow(tubular) or solid in lateral section.

[0052] The movement of each pail lid 65 into position for insertion of agasket 23 begins with a supply of pail lids at an upstream location orstorage site. The delivery of the pail lid 65 can be automated in thesense of a conveyorized scheme or a pick-and-place apparatus design.Manual loading of the pail lids, one-by-one, is also an option. Aconveyorized apparatus arrangement for transport of the pail lids can beused with the present invention structure illustrated in FIGS. 1, 2, 3,and 12. Regardless of the specific transport design, the pail lids aresequentially staged or arranged upstream from the gasket insertionlocation which is effectively a location concentric with mandrel 29. Theillustration of multiple pail lids 65 is intended to diagrammaticallyillustrate the various positions or stages of pail lid movement.

[0053] The pail lid transport apparatus 74 which is illustrated includesa pail lid pushing pneumatic air cylinder 75 with a push rod 76threadedly attached to piston 77. Cylinder 75 provides horizontal travelfor any pail lid 65 which is positioned at location 78. The distance oftravel moves the pail lid from location 78 to location 79. Also includedas part of apparatus 74 is a second pneumatic air cylinder 80 which isarranged for raising any pail lid 65 which is positioned at location 78.Once a pail lid 65 is properly positioned at location 78, cylinder 80 isenergized to raise the pail lid into position adjacent the lower lip 48of mandrel 29 so that a gasket 23 can be inserted into the groove 67 ofthat pail lid, as has been described. As shown by step 2 in FIG. 5, thepail lid is raised into position adjacent lower lip 48 before thelowermost gasket 23 is singulated from the stack 24.

[0054] Once the gasket 23 is fully inserted into pail lid groove 67,this pail lid-gasket assembly 81 is then lowered by the retraction ofthe piston of cylinder 80 back to location 78. From this location thepail lid-gasket assembly 81 is moved downstream to a subsequent use,storage, shipping, or inspection, etc., station at location 79. Thespecific configuration of conveyors and other handling devices for thepail lid, both before and after gasket insertion, is optional asvirtually any number of configurations and devices are suitable tosequentially position pail lids at location 78 and to remove thecompleted assembly 81 from location 79. As explained, while a fullyautomated production line would likely include an automated arrangementfor transport of the pail lids, manual positioning and removal is anoption.

[0055] With references to FIGS. 4-11, eight steps associated with thegasket singulation and insertion method, according to the presentinvention, are illustrated. Although these steps are sequential to oneanother and, while they cover the entire process of both gasketsingulation and insertion into a pail lid, the first three stepsrepresented by FIGS. 4-6 are generally thought of as gasket singulationsteps. The next three steps, as represented by FIGS. 7-9, are generallythought of as gasket insertion steps. The last two steps of the eightsteps illustrated, see FIGS. 10 and 11, are directed more to returningthe singulation and insertion mechanisms to their beginning or startinglocation to continue with a new singulation and insertion cycle.Notwithstanding this partitioning of the eight steps, the followingexplanation will consider these eight steps as eight sequential steps inthe entire cycle, beginning with gasket singulation, extending throughgasket insertion, and returning all settings to the starting point forthe next cycle to begin. Included as part of FIGS. 4-11, correspondingto these eight steps, is the hardware and components of the presentinvention. Since this hardware and components have already beendescribed in conjunction with FIGS. 1, 2, 3, and 12, an important aspectof FIGS. 4-11 is to recognize the state or condition of each cylinderand to actually see the various pistons, rods, etc., as either extendedor retracted. Step 1 of the present invention begins with theillustration of FIG. 4. In this specific condition or arrangement, thefollowing status exists for each of the various cylinders:

[0056] For Step 1 (FIG. 4): Cylinder No. Condition of Cylinder 31Extended 37a Retracted 37b Retracted 42 Retracted 57 Retracted 60Extended 75 Retracted 80 Retracted

[0057] Step 2 of the gasket singulation and insertion method of thepresent invention is illustrated by FIG. 5. In this specific condition,the hardware and components of the present invention have the followingstatus:

[0058] For Step 2 (FIG. 5): Cylinder No. Condition of Cylinder 31Retracted 37a Extended 37b Extended 42 Retracted 57 Retracted 60Extended 75 Retracted 80 Extended

[0059] Step 3 of the gasket singulation and insertion method of thepresent invention is illustrated by FIG. 6. In this specific condition,the hardware and components of the present invention have the followingstatus:

[0060] For Step 3 (FIG. 6): Cylinder No. Condition of Cylinder 31Retracted 37a Extended 37b Extended 42 Extended 57 Retracted 60 Extended75 Retracted 80 Extended

[0061] Step 4 of the gasket singulation and insertion method of thepresent invention is illustrated by FIG. 7. In this specific condition,the hardware and components of the present invention have the followingstatus:

[0062] For Step 4 (GIG. 7): Cylinder No. Condition of Cylinder 31Extended 37a Retracted 37b Extended 42 Extended 57 Extended 60 Extended75 Retracted 80 Extended

[0063] Step 5 of the gasket singulation and insertion method of thepresent invention is illustrated by FIG. 8. In this specific condition,the hardware and components of the present invention have the followingstatus:

[0064] For Step 5 (FIG. 8): Cylinder No. Condition of Cylinder 31Extended 37a Retracted 37b Retracted 42 Retracted 57 Extended 60Retracted 75 Retracted 80 Extended

[0065] Step 6 of the gasket singulation and insertion method of thepresent invention is illustrated by the following condition, thehardware and components of the present invention have the followingstatus:

[0066] For Step 6 (FIG. 9): Cylinder No. Condition of Cylinder 31Extended 37a Retracted 37b Retracted 42 Retracted 57 Retracted 60Extended 75 Retracted 80 Retracted

[0067] Step 7 of the gasket singulation and insertion method of thepresent invention is illustration by FIG. 10. In this specificcondition, the hardware and components of the present invention have thefollowing status:

[0068] For Step 7 (FIG. 10): Cylinder No. Condition of Cylinder 31Extended 37a Retracted 37b Retracted 42 Retracted 57 Retracted 60Extended 75 Extended 80 Retracted

[0069] Step 8 of the gasket singulation and insertion method of thepresent invention is illustrated by FIG. 11. In this specific condition,the hardware and components of the present invention have the followingstatus:

[0070] For Step 8 (FIG. 11): Cylinder No. Condition of Cylinder 31Extended 37a Retracted 37b Retracted 42 Retracted 57 Retracted 60Extended 75 Retracted 80 Retracted

[0071] The sequence of cylinder retraction and extension movementsdetailed for steps 1-8, as represented by FIGS. 4-11, must becoordinated such that for critical steps one cylinder piston is notretracted before another piston is extended, or vice versa. For example,in step 2, cylinders 37 a and 37 b are to be extended for gasketsingulation and cylinder 31 is retracted. In order to prevent the stack24 of gasket 23 from dropping lower on the mandrel 29, the piston 34 ofcylinder 31 must not be retracted until piston 44 of each of the fourcylinders 37 b has been fully extended so that the stack 24 will besupported by the tips 44 a of pistons 44 once cylinder pistons 38 areretracted.

[0072] In accordance with the teachings of the present invention, and asis shown, a variety of pneumatic control modules and timing circuits canbe used to precisely sequence and control the extension and retractionmovements, and the duration of each, for each cylinder. By knowing andcontrolling when each cylinder is activated or energized to change itsstate and by controlling the time duration in each state, steps 1-8 ofFIGS. 4-11 are accurately and precisely performed. Design enhancementsor modifications to using only pneumatic control modules and timingcircuits include the use of optical sensors. Such sensors are positionedso as to be able to sense when a specific piston is retracted and/orwhen it is extended. Once a particular piston is sensed as being inposition, then a sequential piston movement can be initiated. Forexample, once again using cylinders 31, 37 a, and 37 b for the example,optical sensors would be arranged to generate corresponding controlsignals once the four pistons 44 are fully extended. Receipt of thefourth control signal signifies that all four pistons 44 are in positionand that the four cylinders 31 can be energized to retract the pistons34.

[0073] Optical sensors can also be used to verify when the stack 24 isin position on the mandrel and when the lowermost gasket 23 has beensingulated and is resting on lower lip 48, ready for insertion into thepail lid 65. In order to preclude the (premature) use of cylinders 57for gasket insertion, it is necessary to verify that a pail lid has beenraised into position at the bottom of the mandrel. While the extendedcondition of cylinder 80 could be one indication of a pail lid inposition, that is true only if a pail lid was initially properly placedat location 78. Consequently, the use of an optical sensor is preferredto actually verify that a pail lid has been raised into position beforeenergizing cylinders 57 and 60 for the gasket insertion step.

[0074] Referring now to FIGS. 13-23, a second embodiment of the presentinvention is illustrated. Included as part of this second embodiment isthe gasket singulation and insertion mechanism 120 and its method of usefor insertion of a singulated gasket 121 into a pail lid 122.

[0075] Mechanism 120 includes a first station 123 for the stacking andpresentation of the individual gaskets 121. While a series of individualgaskets 121 can actually be loaded at station 123, the preferredembodiment will utilize a web-connected stack 124 of gaskets 121 whichwill be loaded as an integral unit into a double-sleeved mandrel nest125. The inner cylindrical wall 126 of mandrel nest 125 and theconcentric outer cylindrical wall 127 are spaced apart a distance whichis just slightly greater than the lateral cross sectional diameter ofthe corresponding gaskets as part of stack 124 to be positioned betweenthe two concentric cylindrical walls 126 and 127.

[0076] While a variety of support and lift or push mechanisms can beused to support and raise the stack 124 of gaskets 121 which ispositioned between the concentric pair of cylindrical walls 126 and 127,the preferred mechanism uses lift rods connected to a ball screw.

[0077] By positioning an abutment floor or stationary annular ring 130between the inner and outer walls 126 and 127, the axial depth of theannular clearance space 131 can be selected based on the axial height ofthe stack 124 of gasket 121 to be loaded into mandrel nest 125. It isalso envisioned as part of the present invention that the “stationary”annular ring 130 can be adjusted as to its axial depth to accommodatevarying heights for stack 124.

[0078] A lift platform 132 is positioned below the mandrel nest 125 andis acted upon by the piston 133 of ball screw device 134. Connected toplatform 132 are a series of four equally-spaced lift rods 135 arrangedinto a circular pattern. Each lift rod 135 extends axially upwardly inthe direction of stack 124. The stationary annular ring 130 isperforated with circumferential clearance apertures equal in number andcorresponding in spacing to the lift rods 135. Each lift rod 135 extendsup into and through a corresponding aperture in the stationary annularring 130 such that each lift rod is able to push in an upward directionon the lower surface of the stack 124 of gaskets 121, at fourequally-spaced locations, in order to raise the entire stack 124.Raising stack 124 allows the uppermost gasket 121 a of that stack to bepositioned adjacent to and immediately above the uppermost edges 126 aand 127 a of the inner and outer walls 126 and 127, respectively. Analternative construction uses the lift rods 135 to actually pushupwardly on the annular ring 130 to raise the stack 124 of gaskets. Inthis alternative construction, the annular ring 130 is not stationary,but actually moveable.

[0079] In operation, the ball screw device 134 is energized so as topush upwardly on platform 132 which in turn pushes upwardly on theseries of lift rods 135. As these lift rods 135 travel upwardly throughthe apertures in the annular ring 130, the upper ends of the lift rods135 push against the bottom surface of the lowermost gasket 121 b in theweb connected stack 124. Once the uppermost gasket 121 a clears theupper edges 126 a and 127 a of walls 126 and 127, respectively, anoptical sensor 136 (i.e., electric eye) watches for the uppermost gasket121 a. Once the uppermost gasket 121 a clears the upper edges of theinner and outer walls 126 and 127, an electrical signal is sent to theball screw device 134 instructing it to stop. This then fixes theuppermost gasket 121 a at a location just above the upper edges 126 aand 127 a of the inner and outer walls.

[0080] As illustrated in FIG. 13, the outer cylindrical wall 127 can beformed as a partial cylinder with an open front section 127 b. Thisallows the stack 124 of gasket 121 to be viewed and to be adjusted oruntangled if problems might develop. This open section also allows theuse of a gasket clamping arrangement 138. As will be explained, theuppermost gasket 121 a is to be singulated from stack 124 so that it canbe transported to the insertion station for inserting the singulatedgasket into a corresponding pail lid. As the uppermost gasket 121 a issingulated from the stack 124, it is important that the remainder of thegaskets in stack 124 remain stationary and not be pulled free or pulledout of the annular clearance space 131.

[0081] The next step in the gasket singulation process is to use a pairof gripping mechanisms 139 and 140 which are positioned above the stack124 of gaskets 121 along one side. By the use of cylinders 141 and 142,the two gripping mechanisms 139 and 140 are manipulated so as to griponto the uppermost gasket 121 a and pull it upwardly away from theremainder of stack 124, see FIGS. 15 and 16. With the remaining gasketsof the stack 124 clamped onto by clamping arrangement 138, this beginsthe tearing of the molded web of material connecting the uppermostgasket 121 a with the remainder of the stack 124. As this singulationprocess begins and the separation of the uppermost gasket 121 a begins,a separating rod 145 is used to facilitate the singulation. During thetravel of rod 145 horizontally across the upper edges 126 a and 127 a,the gripping mechanisms 139 and 140 continue to grip onto the uppermostgasket 121 a. Cylinder 146 is energized to effect travel of piston 147which is connected to the separation rod 145. The extended traveldistance of piston 147 is such that it pushes rod 145 completely acrossthe two cylindrical walls 126 and 127, see FIG. 17.

[0082] With gasket 121 a singulated, cylinders 141 and 142 are thenretracted and this pulls the singulated gasket 121 a into position abovepail lid 122 at the insertion station 148, see FIG. 18. During this samestep in the overall process, the piston 147 of cylinder 146 is retractedso as to pull the separating rod 145 back to the start position, readyfor singulation of the next gasket of the stack 124.

[0083]FIGS. 19, 20, and 21 illustrate the concluding steps to theprocess. With the singulated gasket 121 a in position above the pail lid122 and being arranged substantially concentric with the receivinggroove 151 (see FIG. 22) of the pail lid 122, the insertion processbegins.

[0084] The actual insertion process and the use of the insertionmechanism 152 is illustrated in FIGS. 22 and 23. Insertion mechanism 152is securely connected to the piston 153 of cylinder 154 for axialmovement (i.e., raising and lowering) of mechanism 152. Pail lids 122are sequentially delivered to the insertion station 148 and becomepositioned between opposed pail lid clamps 155 and 156 which are movabletoward and away from the pail lid by the action of cylinders 157 and158, respectively.

[0085] The pail lid 122 which is positioned for gasket insertion atstation 148 is positioned on a pail lid rotation unit 161. Rotation unit161 includes a lift cylinder 162 and a turntable 163 whose axial heightis controlled by cylinder 162. As the gasket insertion mechanism 152 isoperated, the pail lid 122 rotates so that a different section of theuninstalled gasket is presented to insert drive roller 164 of mechanism152. In operation, a pail lid 122 is positioned at the insertion station148 between clamps 155 and 156 and concentric with turntable 163, eventhough the turntable is not yet raised into contact with the pail lid122. The positioning of the pail lid can be performed while the gasket121 to be inserted into the receiving groove 151 is being singulated orcan be moved into position prior to singulation. The next step is toalign the singulated gasket 121 a on the pail lid so as to be generallyaligned with the receiving groove 151. The gripping mechanisms 139 and140 are released as the lift cylinder 162 raises the turntable 163 intocontact with the underside of the pail lid 122. As this action isoccurring, the insertion mechanism 152 is lowered into engagement withthe upper surface of the pail lid by cylinder 154. As mechanism 152 isoperated, the insert drive roller 164 pushes the gasket 121 a into thereceiving groove 151 of the pail lid 122. The rotation of drive roller164 helps to impart rotary motion to the pail lid. Since the pail lid isnow supported by the turntable 163 which freely rotates, the pail lidrotates as the drive roller rotates as part of the gasket insertionprocess.

[0086] Insertion mechanism 152 includes a gear motor 168 which isconnected to drive roller shaft 169 by drive belt 170. The gasket guidepin 171 which is supported by-arm 172 helps to guide and direct thegasket 121 a into position above the receiving groove 151 of the paillid 122. This “upstream” gasket alignment enables the drive roller 164to push the gasket 121 a into the receiving groove.

[0087] Once the gasket is fully installed into the receiving groovethroughout its entire circumference, the pail lid is pushed out ofposition in order to prepare and reset the equipment for gasketinsertion into the next pail lid. The pail lids are preferably fed intoand out of the insertion station 148 by the use of conveyors andcooperating pick-and-place devices.

[0088] While the invention has been illustrated and described in detailin the drawings and foregoing description, the same is to be consideredas illustrative and not restrictive in character, it being understoodthat only the preferred embodiment has been shown and described and thatall changes and modifications that come within the spirit of theinvention are desired to be protected.

What is claimed is:
 1. A gasket singulation apparatus for separating onegasket from a web-connected stack of gaskets, said gasket singulationapparatus comprising: a mandrel for receiving said web-connected stack;first support means for positioning said web-connected stack at apredetermined location relative to said mandrel; separation means forpiercing any web material between a selected pair of axially adjacentgaskets; drive means for axially moving said separation means so as topull one gasket of said selected pair away from the other gasket of saidselected pair; and second support means for supporting those gasketsremaining as part of said web-connected stack as said one gasket isseparated from the original web-connected stack.
 2. A gasket singulationmethod for separating one gasket from a web-connected stack of gaskets,said gasket singulation method comprising the following steps: providinga receiving mandrel; providing a web-connected stack of gaskets;providing a first support member for setting the axial position of saidweb-connected stack of gaskets relative to said receiving mandrel;sliding said web-connected stack of gaskets onto said receiving mandreluntil said first support member is contacted by said web-connected stackof gaskets; inserting a separating member into said web-connected stackof gaskets between the axially lowest gasket and its axially adjacentgasket; inserting a second support member into said web-connected stackof gaskets between the axially lowest gasket and its axially adjacentgasket; moving said first support member out of contact with saidweb-connected stack of gaskets; and axially moving said separatingmember so as to pull said axially lowest gasket away from said axiallyadjacent gasket, said axially moving being of a sufficient distance toseparate said axially lowest gasket from the remainder of saidweb-connected stack.
 3. A gasket insertion apparatus for inserting agasket into a generally annular receiving groove of a pail lid, saidgasket insertion apparatus comprising: a gasket positioning mandreldefining an annular support lip; pail lid positioning means for moving apail lid into a gasket-insertion position adjacent said annular supportlip, said annular receiving groove opening toward said annular supportlip; and gasket insertion means for engaging a gasket which is to bepositioned on said annular support lip, said gasket insertion meansincluding a gasket-contacting portion and two drive mechanisms whereinone drive mechanism is constructed and arranged for moving saidgasket-contacting portion radially and the other drive mechanism isconstructed and arranged for moving said gasket-contacting portionaxially.
 4. A gasket insertion method for inserting a gasket into agenerally annular receiving groove of a pail lid, said gasket insertionmethod comprising the following steps: providing a gasket-receivingmandrel, said gasket-receiving mandrel including an annular support lip;providing a pail lid positioning apparatus; providing a gasket insertionmember for contacting the gasket to be installed in said pail lid;positioning a gasket on said annular support lip; positioning a pail lidon said pail lid positioning apparatus; moving said pail lid to aposition adjacent said annular support lip, said pail lid being orientedsuch that said annular receiving groove opens toward said gasket;radially moving said gasket insertion member toward said mandrel at alocation above said gasket; axially moving said gasket insertion membertoward said gasket; contacting said gasket with said gasket insertionmember as the axial movement continues so as to pull said gasket off ofsaid annular support lip; and pushing said gasket into said annularreceiving groove.